Structural panel



Feb. 24, 1953 Ma M. 'CLEMENTS STRUCTURAL PANEL Filed July 24, 1950 B ama @hn mm m w w. m6

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Patented Feb. 24, 1953 UNITED STATES PATENT OFFICE STRUCTURAL PANELMacMillan Clements, Bethel, Conn. I Application July 24, 1950, SerialNo. 175,607

10 Claims.

This invention relates to structural panels and more particularly toimproved hollow panel units which fit together to form both an inner andan outer wall of a building.

There is a distinct need in the building industry for a low cost, lightweight, strong, dimensionally stable, thermal insulating, long lasting,rodent proof panel which can be used to form both an inner and an outerwall of a building, a refrigerator, or used wherever heat insulatingqualities are desired in a panel of this type. In accordance with thisinvention there is provided a novel panel which meets theserequirements. This panel is characterized by the combination of an innerframe and two flanged facing or closure members whose flanges, incooperation with the frame form a retaining-key-receiving channel orgroove for making a tight seal between the edges of adjacent panels.Other features of the panel include the metal surface skin on one orboth sides thereof, and the provision of offset or overlapping portionsof the panel sides which allow for attaching the panel to frame memberswithout disturbing the vapor seal.

An object of the invention is to provide a new and improved structuralpanel constructed and adapted to form with other panels of likeconstruction, a heat insulated Wall, floor or ceiling.

Another object of the invention is to provide a novel strengthening andvapor sealing constrution for a structural panel.

An additional object is to provide a panel having opposite'facesfprovided with a skin'having heat reflecting and heat dissipatingqualities on one or both sides thereof, to thereby increase the heatinsulating qualities of the panel.

A further object is to provide extension panel means forming part of aside of the panel for attaching the panel'to a structural support.

Another objectis to. provide a panel having metal skins on oppositesides thereof, in which there will be no metalto metal'jcontact betweenthe skins on opposite sides of the panel, and providing a space for akey to attach adjacent panels to each other.

Other objects will appear hereinafter throughout the specification. IThe invention will be better understood from the following descriptiontaken in connection with the accompanying drawing, and its scope will bepointed out in the appended claims.

in the drawing,

Figure l is a perspective view of one form of a panel of this inventionwith parts broken away to show the interior construction,

Figure 2 is a view similar to Figure 1 showing another form of theinvention.-

Figure 3 is a top or bottom plan view of the construction shown ineither Figure 1 or Figure 2.

Figure 4 is an exploded diagrammatical view of the side edges of twopanels with a locking key for joining the same, and

Figure 5 is a horizontal section through the side edges of'two panelsshowing a modification of the structure shown in Figure 4.

Referring now to the drawing and more particularly to Figure 1, thenumeral 14 indicates generally the panel'as a whole. Any number ofthesepanels may be arranged side by side with key means for connectingthem to form the wall, ceiling and-floor construction of a house, refrigerator or other structure such as refrigerating cars of railroad rollingstock, refrigerating trucks, etc. The panel is provided with a metallicskin It which may consist of a sheet of any suitable high tensilestrength material such as, for example, 32 to'28 gauge sheet metal whichmay be stainless steel, aluminum, copper, magnesium, Monel metal or anyother suitable material, but is preferably a metallicsheet. This skinhas side flanges I1 and H3.

The skin forms part of the facing member that includes a relativelythick backing sheet of low tensile strength material such as plywoodconsisting of the three ply sheet shown having layers I9, 20 and 2|which are connected adhesively bonded to each other and to the skin It.This laminated sheet, comprising the several layers and skin, isattachedto a rectangular or other shaped frame work that may consist of an upperframe piece 22, a lower similar frame piece 42 and two side frame pieces24 and 25. The upper frame pieces are attached to the lower frame piecesbut any suitable means such as nails 23, and. the facing member as awhole is attached to the upper and lower frame pieces by attaching meanssuch as nails 48.

The opposite face of the panel is constructed in a similar manner, butis provided with extension frame members 3| and t3 which extend beyondthe upper and lower extremities of the sheet 16 and the first describedor main frame. This panel face consists of a sheet of material forming askin 33 and the backing sheet is composed preferably of three layers ofplywood 34, 35 and 35 bonded by a suitable adhesive to each other and tothe skin 33 the layers of material forming a laminated sheet. This skinhas right angle flanges 30 and 86 and the plywood layers all of whichare bonded to each other and are provided with right angle flanges 26,21, and 28.

Each extension frame member further includes the thick laminations 38,39 and 40 bonded. to each other and to the backing sheet. Preferably,laminations 38, 39 and 49 terminate at the top surface of frame member22 and bottom surface of frame member 42, but they may be continuoussheets that are of the same length as the metal skin 33 and its backingsheet in order to add strength to the panel. Securingmeans, such asnails 29 are used to secure the parts together, as shown. Flanges l1 andi8 and the backing sheet are secured to the frame work by securing meanssuch as nails 48.

Extending entirely through the upper and lower extension frame members3| and 43 are metal lined apertures 32, 44 and 46 for the reception oflag screws or other securing means for attachment to suitable supports,such as runner I5. It will be understood thatthe top of frame 22 andextension-frame 3! will be flush with a similar runner, not shown,when-the panels are put in place.

The opposite faces together with the side faces over which the flangesextend, of the several frame members, form the support for the laminatedsheets. The insulated interior of the panel as defined by the framemembers 22, 24, -25 and 42 provides-with the laminated sheets a spacewhich may be an air space. Preferably, however, this space is filledwith a suitable insulating material 600.

By referring toFigure 1, it will be noted that the metal sheets ormembers and the'backing layers forming the flanges on bothof the sideedges of'the panel terminate short of each other so as to leaveaspace-in order that there will be no metalto metal contact or even abacking sheet contact between the sheets forming the-opposite faces andside edgesof the panel.

When a plurality ofpanels are placed side by side to form a wall, anon-heat conducting key or spline is used to fill thespace'between thesepairs of flanges of abuttingpanels so as to lock the side of each panelto an adjoining panel, or a tongue may be formed integral with the partsso as to extend into the'groove of the adjacent panel.

Two forms of locking means are indicated in Figures 4 and 5. In Figure4, as diagrammatically shown, the side edges of a pair ofpanels isindicated by the reference numerals 2, '2. These panels maycorrespond-structurally to the panels shown in Figures 1, 2-and 3. Thegrooves-indicated formed in the side edges of such panels are shown at land there'is a locking key or spline 3 preferably of wood or other heatnon-conducting material which serves'to lock the side edges of eachadjacent pair of panels.

It will be understood that Figure 4 merely indicates the connectionbetween side edges of the panels, the detailed construction of thepanels being shownin Figures 1 to 3. As shown in Figure 5, panels 4 and6V are constructed'in accordance with the panels above described. Theside edges of the panels indicated by numerals 4 and 6 as provided witha tongue portion which is adapted to enter thecorrespondinggroove 7 inthe adjacent panel. It will, of course, be understood that each panelwill be provided with a groove on one side edge and a tongue on theopposite side edge so that a plurality of panels may be connected toeach other toform a wall, ceiling or floor of a building, walk-inrefrigerator 4 or other type of refrigerator, or similar structures.

The key 3 of Figure 4 and tongue 5 of Figure 5 preferably extend theover all length of the panel to thereby provide an air seal, andfurther, to provide an insulating layer between the inner and outermetal skins of the panels.

When either the key or the integral tongue is used it should be of thesame length as the greatest longitudinal dimension'of the panelincluding the extension frame members, and therefore extend beyond thegroove at the upper and lower ends thereof, so as to form a sealing andlocking connection between the adjacent sides of each pair of panels forthe entire vertical .distance of the panel as viewed in Figures 1 and 2.

Referring to Figure 2, it will be noted that the construction shown isthe same as that shown in Figure 1 except the extension frame members,including the extensionsof the skin and backing member, are on oppositefaces of the sheet. In this constructiomthe panel is indicated generallyby the'numeral 5!, the metal flange being indicated by 53 with theplywood sheets shown at 54, 55 and 56 of one of the facing sheets. Theseare attached to the opposite-sides of a pair of main frame members H,12, and to the ends of the other pair of frame members 8! and l H) bysuit able means such as the nails 52, as shown in Figure 2.

The opposite facing sheet is indicated by numeral 63 having flanges 62and 73, the plies of the backing sheet being indicated by the numerals68, 69 and T0. In the construction shown in Figure 2, the vertical framemembers shown are at-5'l and 75 and'they are preferably dup1icates ofeach other. These offset extension frame members are on opposite sideedges of the panel.- The lower extension frame member may be fastened torunner indicated in dotted lines and the upper extension frame membermay be attached to a similar upper-runner, not shown, by lag screws thatextend through apertures 84, 65 and 96 in said extension frame members.

The skin 50 has flanges 53 on opposite sides and the backing member thatincludes bonded sheets E9, Biland 8| havingv flanges 54, 55 and 55 onboth side edges. All of these flanges 53 to 55 are preferably attachedto the main frame pieces H and 72, and extension 15 by nails 52.

The skin 53 has flanges 62 on opposite sides of the backing member thatincludes sheets 68, 69, and Hi, all bonded to each other and to theskin.

The flanges 62 and 13 of the skin and flanges of the backing member. areheld in place on the vertical framemembers 'H and I2 and on theextension frame member 51 preferably by nails 14.

The extension frame member 51 preferably includes several pieces orthick plies 5B, 59 and 69 bonded to each other and the backing memberincluding the flanges thereof.

Extension frame members 3| and 43 of Figure 1 are members whichpreferably terminate at the upper-and lower frame pieces 22 and 42respectively. It will be understood, however, that said extensionmembers may be a single board extending the entire length of the skin 33andbacking layer.

It will be noted that the frame members of each of the figures arepreferably constructed of wood, as shown.

Referring to Figure 3, the top frame member 22, skin l6, l7, l9, 20, 2l,22 and attaching means 23 are the same as these parts indicated inFigure 1. The flanges consist of the metal skin flanges l1 and I8 asshown in igure 1 and the plies i9, 20 and 2|, and 26, 21 and 28 beneathmetal flanges I i, i8 and 3t, 86 respectively.

The extension frame member as in Figure 1 is composed of thick sheets orplies of wood or other material bonded to each other and to skin 33. Theinner surface of the extension frame member may have a face piece 4| asshown in Figures 1 and 3.

It will be understood that the construction shown in Figure 3, althoughthe parts correspond to Figure 1, correspond to the same parts as wouldbe shown by Figure 2.

It will be further appreciated that the various layers of the backing,as well as the extension frame, may be made of various fibrous or othermaterials having the desired insulating qualities.

Referring again to the structure shown in Figures 1 to 3, for instance,there may be substituted for the three-ply sheet i9, 23 and 2!, or 38,39 and ill, or 54, 55 and 56 or 58, 5t and fill or 68, 69 and ill, asingle hard board sheet in substitution of the three sheets of compositematerial suitable for the purpose. In fact sheets of any material may besubstituted for the composite sheets which provide the requisitestrengthening and heat insulating qualities.

Extension members 58 and may extend for the entire longitudinal distanceor heighth of the skins and backing members, but preferably extensionmember 58 does not extend beyond the lower horizontal edge of the upperframe member Bi and extension frame member f5 preferably extends nofurther upwardly than the upper horizontal edge of the lower framemember I iii.

A typical dimension for the panel is 2 feet wide by 8 feet high forhouse walls and walk-in freezers, but either or both of these dimensionswill vary according to specific requirements. The vapor space may beabout 4% inches across, but where high insulation requirements prevail,the width may be 12 inches or more.

In order to provide additional insulation, another layer of plywood maybe bonded to the 3-ply plywood. Interposed between the plywood plies isan additional seal comprising the layers 38 and 48 to which is attachedthe inner layer M by binding material such as waterproof glue or anyother adhesive material suitable for the purpose.

What I claim as new and desire to secure by Letters Patent is:

1. A panel for use in building construction and refrigerators comprisingin combination, a frame having a first pair and a second pair ofopposite faces, two laminated sheets of material, said laminated sheetsextending across said first pair of opposite faces of said frame so asto form with said frame an enclosed space, each of said laminated sheetsof material being of a larger area than the area defined by said frameover which they extend with the ends of said laminated sheets extendingbeyond the opposite side edges of said frame, forming right angleflanges on the second pair of opposite faces of said frame attachingmeans attaching each set of sheets to said second pair of opposite facesof said frame but each said pair of flanges terminating short of eachother forming with said last mentioned faces, retaining key-receivingchannels with the side flanges spaced from each other, said chan nelsextending along both of said second pair of said opposite faces, eachlaminated sheet and its flanges comprising an outer metallic sheet andan inner non-metallic sheet of material said metallic sheet andnon-metallic sheet of material being bonded to each other to form eachsheet of laminated material.

2. A panel for use in building construction and refrigerators comprisingin combination, a frame having a first pair and a second pair ofopposite faces, two laminated sheets of material, said laminated sheetsextending across said first pair of opposite faces of said frame so asto form with said frame an enclosed space, each of said laminated sheetsof material being of a larger area than the area defined by said frameover which they extend with the ends of said laminated sheets extendingbeyond the opposite side edges of said frame, forming right angleflanges on the second pair of opposite faces of said frame attachingmeans attaching each set of sheets to said second pair of opposite facesof said frame but each said pair of flanges terminating short of eachother forming with said last mentioned faces, retaining key-receivingchannels with the side flanges spaced from each other, said channelsextending along both of said second pair of said opposite faces, eachlaminated sheet and its flanges comprising an outer metallic sheet andan inner non-metallic sheet of material, at least one of saidnon-metallic sheets of material comprising a plywood layer said metallicsheet and non-metallic sheet of material being bonded to each other toform each sheet of laminated material.

3. A panel for use in building construction and refrigerators comprisingin combination, a frame having a first pair and a second pair ofopposite faces, two laminated sheets of material, said laminated sheetsextending across said first pair of opposite faces of said frame so asto form with said frame an enclosed space, each of said laminated sheetsof material being of a larger area than the area defined by said frameover which they extend with the ends of said laminated sheets extendingbeyond the opposite side edges of said frame, forming right angleflanges on the second pair of opposite faces of said frame attachingmeans attaching each set of sheets to said second pair of opposite facesof said frame but each said pair of flanges terminating short of eachother forming with said last mentioned faces, retaining key-receivingchannels with the side flanges spaced from each other, said channelsextending along both of said second pair of said opposite faces, eachlaminated sheet and its flanges comprising an outer metallic sheet andan inner non-metallic sheet of material, each of said non-metallicsheets of material comprising a plywood layer said metallic sheet andnonmetallic sheet of material being bonded to each other to form eachsheet of laminated material.

4. A panel for use in building construction and refrigerators comprisingin combination, a frame having a first pair and a second pair ofopposite faces, two laminated sheets of material, said laminated sheetsextending across said first pair of opposite faces of said frame so asto form with said frame an enclosed space, each of said laminated sheetsof material being of a larger area than the area defined by said frameover which they extend with the ends of said laminated sheets extendingbeyond the opposite side edges of said frame, forming right angleflanges on the second pair of oppositeifaces of said frame attachingmeans attaching each set of sheets to said second pair of opposite facesof said frame but each said pair of flanges terminating short of eachother forming withsaid last mentioned faces, retaining key-receivingchannels with the side flanges spaced from each other, said channelsextending along both of said second pair of said opposite faces, eachlaminated sheet and its flanges comprising an outer metallic sheet andan inner non-.metallic sheet of material, said metallic sheet andnon-metallic sheet of material being bonded to each other to form eachsheet of laminated material, said fastening means for attaching saidlaminated sheets to said second pair of opposite faces of said framemembers extending through the flanges of both the outer metallic sheetand the inner non-metallic sheet of each laminated sheet.

5. A panel for use in building construction and refrigerators comprisingin combination, a frame having a first pair and a second pair ofopposite faces, two laminated sheets of material, said laminated sheetsextending across said first pair of opposite faces of said frame so asto form with said frame an enclosed space, each of said laminated sheetsof material being of a larger area than the area defined by said frameover which they extend with the ends of said laminated sheets extendingbeyond the opposite side edges of said frame, forming right angleflanges on the second pair of opposite faces of said frame attachingmeans attaching each set of sheets to said second pair of opposite facesof said frame but each said pair of flanges terminating short of eachother forming with said last mentioned faces, retaining key-receivingchannels with the side flanges spaced from eachother, said channelsextending along both of said second pair of said opposite faces, eachlaminated sheet and its flanges comprising an outer metallic sheet andan inner non-metallic sheet of material, at least one of saidnon-metallic sheets of material comprising a plywood layer, saidfastening means for attaching said sets of sheets to said second pair ofopposite faces of said frame members extending through the bent-overends of both the outer metallic sheet and the inner non-metallic sheetof each set of sheets.

6. A panel for use in building construction and refrigerators comprisingin combination, a frame having a first pair and a second pair ofopposite faces, two laminated sheets of material, said laminated sheetsextending across said first pair of opposite faces of said frame so asto form with said frame an enclosed space, each of said laminated sheetsof material being of a larger area than the area defined by said frameover which they extend with the ends of said laminated sheets extendingbeyond the opposite side edges of said frame, forming right angleflanges on the second pair of opposite faces of said frame attachingmeans attaching each set of sheets to said second pair of opposite facesof said frame but each said pair of flanges terminating short of eachother forming with said last mentioned faces, retaining key-receivingchannels with the side flanges spaced from each other, said channelsextending along both of said second pair of said opposite faces, eachlaminated sheet and its flanges comprising an outer metallic sheet andan inner non-metallic sheet of material, said metallic sheet andnon-metallic sheet of material being bonded to each other toform eachsheet of laminated material, said frame having an extension meanswhereby to provide a stepped structure, said extension means providingan extension for attaching said panel to a structural support.

7. A panel for use in building construction and refrigerators comprisingin combination, a frame having afirst pair and a second pair of oppositefaces, two laminated sheets of material, said laminated sheets extendingacross said first pair of opposite faces of said frame so as to formwith said frame an enclosed space, each of said laminated sheets ofmaterial being of a larger area than the area defined by said frame overwhich they extend with the ends of said laminated sheets extendingbeyond the opposite side edges of said frame, forming right angleflanges on the second pair of opposite faces of said frame attachingmeansattaching each set of sheets to said second pair of opposite facesof said frame but each said pair of flanges terminating short of eachother forming with said last mentioned faces, retaining key-receivingchannels with the side flanges spaced from each other, said channelsextending along both of said second pair of said opposite faces, eachlaminated sheet and its flanges comprising an outer metallic sheet andan in er non-metallic sheet of material, each of said non-metallicsheetsof material comprising a plywood layer, said metallic sheet andnoninetallic sheet of material being bonded to each other to form eachsheet of laminated material, said frame having an extension meanswhereby to provide a stepped structure, said extension means providing aplurality of extensions for attaching said panel to structural supports,said extension means further including metallic sheet and a non-metallicsheet forming part of each laminated sheet.

8. A panel for use in building construction and refrigerators comprisingin combination, a frame having a first pair and a second pair ofopposite faces, two laminated sheets of material, said laininated sheetsextending across said first pair of opposite faces of said frame so asto form with said frame an enclosed space, each of said laminated sheetsof material being of a larger area than the area defined by said frameover which they extend with the ends of said laminated sheets extendingbeyond the opposite side edges of said frame, forming right angleflanges on the second pair of opposite faces of said frame attachingmeans attaching each set of sheets to said second pair of opposite facesof said frame but each said pair of flanges terminating short of eachother forming with said last mentioned faces, retaining key-receivingchannels with the side flanges spaced from each other, said chan nelsextending along both of said second pair of said opposite faces, eachlaminated sheet and its flanges comprising an outer metallic sheet andan inner non-metallic sheet of material, said fastening means forattaching said sets of sheets to said second pair of opposite faces offrame members extending through the flanges of both the outer metallicsheet and the inner nonmetallic sheet of each laminated sheet, saidmetallic sheet and non-metallic sheet of material being bonded to eachother to form each sheet of laminated material, said frame having anextension means whereby to provide a stepped structure, said extensionmeans providing a plurality of extensions for attaching said panel tostructural supports, said extension means further including a metallicsheet and a non-metallic sheet forming part of each laminated sheet.

9. A panel for use in building construction and refrigerators comprisingin combination, a frame having a first pair and a second pair ofopposite faces, two laminated sheets of material, said laininated sheetsextending across said first pair of opposite faces of said frame so asto form with said frame an enclosed space, each of said laminated sheetsof material being of a larger area than the area defined by said frameover which they extend with the ends of said laminated sheets extendingbeyond the opposite side edges of said frame, forming right angleflanges on the second pair of opposite faces of said frame attachingmeans attaching each set of sheets to said second pair of opposite facesof said frame but each said pair of flanges terminating short of eachother forming with said last mentioned faces, retaining key-receivingchannels with the side flanges spaced from each other, said channelsextending along both of said second pair of said opposite faces, eachlaminated sheet and its flanges comprising an outer metallic sheet andan inner non-metallic sheet of material, each of said non-metallicsheets of material comprising a plywood layer, said fastening means forattaching said laminated sheet to said second pair of opposite faces ofsaid frame members extending through the flanges of both the outermetallic sheet and the inner non-metallic sheet of each set of sheets,said metallic sheet and non-metallic sheet of material being bonded toeach other to form each sheet of laminated material, said frame havingan extension means whereby to provide a stepped structure, saidextension means providing a plurality of extensions for attaching saidpanel to structural supports, said extension means further including ametallic sheet and a nonmetallic sheet forming part of each laminatedsheet, said extension means extending below and above said frame and onthe same side thereof.

10. A panel for use in building construction, and for refrigerator wallsand floors comprising in combination, a rectangular frame having a firstpair and a second pair of opposite faces, two laminated sheets ofmaterial, said sheets extending across said first pair of opposite facesof said frame so as to form with said frame an enclosed space,insulating material in said enclosed space, each of said laminatedsheets of material being of larger area than the area defined by saidframe 10 over which they extend whereby the ends of said laminatedsheets extend'beyond the opposite side edges of said frame, said endsextending beyond the frame side edges extending at right angles to thefirst pair of opposite frame faces and parallel to said second pair ofopposite frame faces and forming right angle flanges, said laminatedsheet ends terminating short of each other on said second pair ofopposite frame faces so as to form with said last-named frame facesretaining keyreceiving channels between each pair of opposed sheet endsof each sheet, said channel extending along both said opposite framefaces, each laminated sheet and its flanges comprising an outer metallicskin having heat reflecting and dissipating qualities and an innersupporting sheet of non-metallic material, and means for attaching saidsheet ends to said second pair of opposite frame faces, said metallicsheet and non-metallic sheet of material being bonded to each other toform each sheet of laminated material, said frame having a plurality ofextension means whereby to provide a stepped structure, one extending upwardly on one side of said frame and the other extending downwardly onthe opposite side of said frame.

MACMILLAN CLEMENTS.

REFERENCES CITED The following references are of record in the file ofthis patent:

UNITED STATES PATENTS Number Name Date 1,540,542 Carhart June 2, 19251,669,667 Levine May 15, 1928 1,683,966 Forster Sept. 11, 1928 2,125,286Fletcher Aug. 2, 1938 2,149,882 Clements Mar. '7, 1939 2,165,336 BrogdenJuly 11, 1939 2,200,159 Davis May 7, 1940 2,307,080 Schaefer Jan. 5,19%3 2,585,961 Norquist Feb. 19, 1952

